Respiratory Hazards in Welding, Cutting, and Brazing Operations
The Problem
Welding, cutting, and brazing release toxic fumes and gases that can seriously harm your lungs and long-term health. These microscopic particles and airborne contaminants can cause both immediate irritation and chronic respiratory diseases if proper precautions are not taken. Today, we’ll discuss the dangers of exposure and how to protect yourself from hazardous air contaminants.
Identify the Hazards
How Welding Fumes Are Created
- When metals are heated, they evaporate, cool, and form fine airborne particles that can be inhaled.
- Paint, rust inhibitors, galvanised coatings, and other surface treatments produce additional toxic gases.
Types of Toxic Fumes and Gases
- Common metals: Iron, manganese, lead, zinc, and hexavalent chromium.
- Additional contaminants: Gases and particulates from flux coatings, shielded gas welding, and other metal treatments.
Symptoms of Exposure
- Headaches, dizziness, shortness of breath, and irritation of the eyes, nose, or throat.
Safety Practices and Preventative Measures
Clean the Work Surface
- Remove paint, rust, grease, and coatings before cutting or welding to reduce the production of hazardous fumes.
Proper Positioning
- When working outdoors, stay upwind of the fume source.
- Indoors, position yourself so that fumes rise away from your breathing zone.
Use Proper Ventilation
- General ventilation: Use fans or extraction systems to reduce airborne contaminants.
- Local exhaust ventilation (LEV): Use fume extractors, hoods, or vacuum nozzles positioned close to the weld point to capture fumes before they reach your breathing space.
Wear Respiratory Protection
- If ventilation is inadequate, wear appropriate respiratory protection, such as a fit-tested respirator approved by your employer. Follow instructions for correct selection, fit, and maintenance.
Monitor and Report Symptoms
- If you experience symptoms such as dizziness, headaches, or breathing difficulty, stop work immediately and report to your supervisor.
Real-Life Case or Scenario
A welder working in a confined space did not use ventilation while welding galvanised steel. The zinc fumes caused metal fume fever, resulting in flu-like symptoms, severe headaches, and shortness of breath. This could have been prevented by cleaning the surface beforehand, using proper local exhaust ventilation, and wearing respiratory protection.
Employee Responsibilities
- Clean surfaces before welding to reduce fume generation.
- Work in a safe position to avoid inhaling fumes.
- Use ventilation systems and approved respiratory protection when required.
- Report any symptoms of exposure immediately to your supervisor.
Employer Responsibilities
- Provide effective general and local ventilation systems and ensure they are operational.
- Supply and maintain fit-for-purpose respiratory protection for workers.
- Monitor air quality in line with WorkSafe NZ exposure limits.
- Train workers to recognise welding fume hazards and how to use control measures correctly.
Discussion & Questions
- “Have you ever experienced symptoms like dizziness or eye irritation while welding?”
- “What do you do to reduce fume exposure or position yourself safely?”
Encourage team members to share their experiences—this helps raise awareness and promote practical solutions.
Commitment/Action Plan
Let’s commit to cleaning surfaces, using proper ventilation, and wearing appropriate respiratory protection whenever required. Starting today, make sure every welding task is carried out with health and safety in mind.
Wrap-Up
Respiratory safety is vital in welding, cutting, and brazing work. By understanding the hazards and consistently following safety procedures, we can reduce exposure, avoid long-term health issues, and protect ourselves and our team. Thanks for being committed to keeping our worksite safe.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA), employers must manage the risks of exposure to hazardous substances, including welding fumes. Key expectations include:
- Keeping worker exposure below WorkSafe NZ’s Workplace Exposure Standards (WES)
- Using engineering controls like ventilation and fume extraction
- Providing respiratory protection when engineering controls can’t eliminate the risk
- Offering training on hazard awareness and safe equipment use
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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